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By C. C. Huang

Rare earth compounds, such as samarium-cobalt compounds and neodymium-icon compounds, are being used more often for the manufacture of permanent magnets, because these materials permit the production of permanent magnets with higher magnetic energy potential than the conventional ferrite magnets. Especially, the recent rapid developments in the field of electronics and electro-technology have demanded an increased production of rare earth magnets. Unlike ferrite, which is typically produced by a wet process, rare earths can be ground and classified either in a wet or dry process. In the past, batch ball mills, through-pass ball mills in circuit with air classifiers, and conventional jet mills were primarily employed for the dry processing. These methods, however, have suffered from the problems, for example, wear and contamination, low product quality In particle size distribution, difficult to adopt inert-gas operation, and high specific energy consumption. In this report, dry processing of rare earth powders will be presented, especially ultrafine grinding with fluidized bed jet mill.

Jan 1, 1993

By E Mare

Recent highly publicised incidences of disastrous containment failures, none more pertinent than the 2019 iron ore tailings dam failure in Brumadinho, have focused the world’s attention squarely on the often-challenging subject of tailings storage. Unwanted ultrafines, that are deemed to be unworthy of further treatment or not to have further saleable value, are therefore a significant issue for mine owners looking to reduce risks and perceptions associated with long-term storage of tailings. In this context, there are strong drivers to identify safer approaches to ultrafine tailings management, especially if it can also lead to increased revenue, together with better water stewardship and environmental outcomes. The better management of tailings needs to be considered from both containment challenge and processing opportunity perspectives. This paper focuses on the latter, reviewing from a technical and economic perspective, the feasibility of more extensive processing and/or reprocessing of specifically iron ore tailings, in a bid to reduce the overall volume for management in long-term storage. Herein the opportunity lies in recovery processing, as much as enhanced thickening and/or mechanical dewatering, and therefore the paper discusses both issues as equally important sides of the same coin. Recent interest in iron ore ultrafines processing and reprocessing studies suggests that the enhanced processing of iron ore tailings offers multiple perceived advantages. Apart from a potential reduction in tailings volume, associated with safer containment, lower environmental impact and improved water management, the prospect of increased revenue from additional Fe recovery presents supplementary motivation for iron ore players to embrace this approach, as further elaborated in this paper.

Nov 8, 2021

By M I. Pownceby, S P. Suthers, V Nunna, G J. Sparrow

Global demand for iron and steel has increased substantially over the past 20 years and there has been a greater focus on developing suitable processing options to treat low-grade hematite-goethite ores containing higher levels of silica and alumina impurities. The processing applicable to reduce the impurity levels in these lower-grade iron ores depends on their mineralogy and a thorough understanding of the process dynamics associated with the separation technology. Different separation technologies used to remove silica and alumina from low-grade iron ores were reviewed. The major concentration methods that may be applied to upgrade lower-grade lump iron ores include magnetic separation, wet and dry heavy media separation, and air-pulsed jigging. The technologies applicable to beneficiating iron ore fines include wet and dry gravity and magnetic separation, flotation, and roasting followed by magnetic separation. It is necessary to investigate the application of separation technologies on a case-by-case basis to select economically viable beneficiation strategies suitable for the particular low-grade iron ore. A commercial flow sheet is expected to involve the implementation of several separation technologies.

Nov 8, 2021

By Y. R. Murthy, S. Angadi, A. K. Bhatnagar, S. K. Tripathy, L. O. Filippov

Dolomite is an essential raw material for the refractory industry, a flux in the iron and steel industry and also for the extraction of magnesium metal. Generally, particle size reduction, screening and classification are used for the preparation of the high-grade sized material for different applications, whereas low-grade fine fractions are not utilised. These fines or low-grade overburdens are dumped at the mine site for future utilisation, which creates environmental issues along with inadequate space management. In the present investigation, a detailed study was carried out to decrease the silica content of the low-grade dolomite fines from Gomardih , India, containing 28.6% CaO and 20.1% MgO along with 8.3% silica. Different process flow sheet options were evaluated with a combination of dry classifier, wet classifier, gravity concentrators as well as flotation. Different process variables were assessed along with mineralogical characterisation to optimise the process for efficient rejection of siliceous gangue minerals. Results indicated that dolomite, calcite and quartz are the major mineral phases present in the ore along with other minor minerals. It was concluded that two-stage flotation was an effective process for the reduction of silica up to below 1% after grinding to a particle size below 212 μm. A process flow sheet with a combination of gravitation air classifier and flotation can produce a concentrate with silica content below 4.5%. Keywords: Dolomite, flux, dry classification, flotation, characterisation, beneficiation

Jan 1, 2020

By I. du Plessis

The metallurgical response of a difficult to treat coal and an easy to treat coal orebody were investigated in terms of the coal yield and the coal quality in a basic coal recovery flowsheet. The purpose of this paper is to show trends and derive principles for the treatment of different coal types. This investigation entailed using the LIMN simulator to simulate the metallurgical response by varying the plant operational parameters. The controllable plant variables investigated were: ?Cyclone size ?Screen and hydro-cyclone cut points ?Medium cut density ?Feed particle size distribution.

Jan 1, 2010

By J. L. Holman

In conjunction with its research program on separation, recovery, and recycling of metal, mineral, and energy-based materials in urban refuse, the U.S. Bureau of Mines is developing means to reuse and recycle plastics discarded in raw municipal waste. Experimental work on plastic waste from a community collection has produced some guidelines for systematic methods of processing, including air classification, cleaning, separation, and use or disposal. Sink-float methods are a practical means of separation into types. Methods for final disposition of the plastic waste include refabrication, thermal decomposition, and incineration.

Jan 1, 1972

By C. T. Philipp

Recycling of waste is much preferred over disposal. This paper discusses the Enviroscience, Inc. (ESI) process, now being commercialized by MetWool, Inc., to recycle hazardous wastes using an extractive metallurgical process which is followed by vitrification of non-reducible metal oxides. In this process, volatile and reducible metals are reclaimed as their respective oxides and elements.

Jan 1, 1995

By H. Y. Ran

Magneto-flotation is a recently developing technology of mineral processing. This technology combines the traditional magnetic separation with flotation and provides a magnetic and buoyant force compound field to separate different minerals based on the differences of magnetism and floatability between useful minerals and gangue minerals. Magneto-flotation is applicable to separate ferromagnetic from nonmagnetic minerals, especially to separate magnetite from floatable gangue minerals. This magneto-flotation column is equipped with pulse electromagnetic field in the middle upper part, a bubble producer and upwell water inlet in the bottom. The pulse time of electromagnetic field in the column can be optionally adjusted and the maximum intensity of pulse magnetic field can reach 35mT. Pulse magnetic field can not only restrain magnetic minerals from entering into the froth layer, but also destroy the magnetic agglomeration to ensure a higher recovery and a higher concentrate grade. The results of experiments with magnetite show that pulse magnetic field has remarkable influence on flotation process. Compared with single flotation, magneto-flotation column can improve the recovery of magnetite by ten percent. After one time?s magneto-flotation processing, the grade of iron concentrate can increase from 65.4% to 69.5%, the content of silicon oxide in iron concentrate decreases from 7.4% to 2.8%, and the total recovery is above 96%.

Jan 1, 2014

By James K. Gowans

Polaris Mine, a Cominco Ltd. property located on Little Cornwallis Island, Northwest Territories, Canada, (Lat. 75°30'), is the world's most northerly base metal mine. Polaris Mine, which commenced operations in late 1981, is characterized by its unique process barge. The lead/zinc concentrator, powerhouse, shops, offices, dry and warehouse have all been incorporated on a 400 ft. long by 100 ft wide by 65 ft high barge. This process barge was constructed in Southern Canada, at Trois Rivieres, Quebec, then towed 3500 miles into its final resting place on the high arctic. This paper describes the unique design of the barge concentrator and deals with the start-up and continuing operation of the Polaris Concentrator.

Jan 1, 1984

By S. G. Gibbs

A new method for predicting the behavior of sucker-rod pumping systems is presented. The pumping system is described by a flexible mathematical model which is solved by means of partial diflerence equations with the aid of computers. Polished rod and intermediate-depth dynamometer cards can be calculated for various bottom-hole pump conditions. The technique permits simulation of a wide variety of operating conditions, both normal and abnormal. The data generated with the new technique are useful in refining the criteria for design and operation of sucker-rod systms. INTRODUCTION Sucker-rod pumping systems are used in approximately 90 per cent of artificially lifted wells. In view of this wide application, it behooves the industry to have a fundamental understanding of the sucker-rod pumping process. Oddly enough, our understanding has been rather superficial. This is evidenced by the semi-empirical formulas which have been used as the basis for design and operation of sucker-rod installations. Thoueh- we have realized the limitations of our methods for many years, it has not been computationally feasible to use more refined techniques. With the advent and widespread use of digital computers, it is now possible to handle the mathematical problems associated with sucker-rod pumping. This paper summarizes a computer-oriented method which can provide greater insight into the sucker-rod pumping process. It is hoped that this technique, and techniques which may evolve from it, will prove to be the tool needed by industry to obtain the most efficient use of rod pumping equipment. THE MATHEMATICAL MODEL Prediction of sucker-rod system behavior involves the solution of a boundary value problem. Such a problem includes a differential equation and a set of boundary conditions. For the sucker-rod problem, the wave equation is used, together with boundary conditions which describe the initial stress and velocity of the sucker rods, the motion of the polished rod and the operation of the down-hole pump. Of these items, the wave equation, the polished rod motion condition and the down-hole pump conditions are of primary importance. Discussion of the mathematical model centers about these factors. ROD STRING SIMULATION WITH THE WAVE EQUATION The one-dimensional wave equation with viscous damp- is used in the sucker-rod boundary value problem to simulate the behavior of the rod string. This equation describes the longitudinal vibrations in a long slender rod and, hence, is ideal for the sucker-rod application. Its use incorporates into the mathematical model the phenomenon of force wave reflection, which is an important characteristic of real systems. The viscous damping effect postulated in Eq. 1 yields good solutions, even though nonviscous effects such as coulcomb friction and hysteresis loss in the rod material are present. Fortunately, the nonviscous effects are relatively small, so the viscous damping approximation used in the wave equation is adequate. The coefficient v is a dimensionless damping factor which is found in field measurements to vary over fairly narrow limits. For mathematical convenience the gravity term is omitted in Eq. 1. The effect of gravity on rod load and stretch can be treated separately, as will be noted later. Since Eq. 1 is linear, the legitimacy of this procedure is easy to demonstrate. POLlSHED ROD MOTION SIMULATION The motion of the polished rod is determined by the geometry of the surface pumping unit and the torque-speed characteristics of its prime mover. By determining the motion of the polished rod, we formulate an important boundary condition. From trigonometrical considerations it can be shown that the position of the polished rod vs crank angle 0 is given by (see Fig. 1) These equations are obtained from the general solution of the "four-bar" linkage problem and can be used to describe the kinematics of any modern beam pumping unit.' If prime mover speed variations are disregarded, the angular velocity of the crank is constant, and Eq. 2 can be used to predict the position of the polished rod vs time. However, the constant-speed condition leading to constant crank angular velocity is only approached in practice: hence, it is better to make provisions for prime mover speed variations in the mathematical model. The speed at which the prime mover runs is determined by its torque-speed characteristics and the torque imposed upon it. The torque that the prime mover "feels" is the net torque arising from the polished rod load and the opposing torque from the counterbalance effect. The

By James N. Brentz

This paper deals briefly with the problem of efficiently selecting the most cost effective haulage truck. Problems and factors are identified that effect productivity and operating cost. Despite the sophistication of computerized vehicle simulation programs, there is a wide disparity in accuracy and methodology, particularly in dealing with the various elements of cost.

Jan 1, 1984

By B. W. Steele

"Dofasco began operations in 1912 as a steel foundry located in Hamilton, Ontario. Today, Dofasco is a fully integrated mill that manufactures hot rolled, cold rolled, galvanized and tinplate steels. Customers include the automotive, construction, tubular, manufacturing, appliance, packaging and steel ser-vice centre industries. Raw steel production and purchased semi-finished steel processed in1994 was 3.5 million net tonnes. Dofasco employs 7300 people at its Hamilton facility.Environmental management at Dofasco is guided by its environment policy and associated commitments. This paper discusses Dofasco’s responsibility for its products as it relates to these commitments. Dofasco is com-mitted to:n the principles of sustainable development that require that activities be conducted in a manner that provides for the present without compromising the ability of future generations to meet their needs. These principles will be integrated into product design, manufacturing and business planning;n managing renewable and non-renewable resources through the responsible application of reduce, reuse, and recycle principles;n minimizing any potential impact of its operations and products on the environment, employees, customers and the community;n continuous improvement of the effectiveness and integrity of our environmental management systems;n developing understanding among all employees about their responsibilities, and assigning the necessary authority; andn meeting the standards set by relevant legislation and international agreements through participation with governments and the diligent application of economically feasible and scientifically sound methods and technologies."

Jan 1, 1996

By C. W. Donnelly, Louise B. Freeman, Coleman D. Hunter

It is with pride that the authors of this paper report. that during 1944 the production of petroleum in Kentucky passed its all-time peak, 9,496,985 bbl. being contributed. The delivery of natural gas, especially from eastern Kentucky, was maintained and possibly exceeded the highest deliveries of the past. To raise the production of oil and gas was not easy with inferior and worn-out equipment and the shortage of skilled labor. Reminiscent of the early days of the industry in the state, particularly in the hills of Elliott County, where mud roads often have gradients of 45º, was the replacement of worn-out trucks and tractors by oxen. Of the total 9,496,985 bbl., 17 per cent was contributed by the part of Kentucky that is east of the Cincinnati arch, as compared with the total of 7,010,776 bbl. contributed in 1943, of which 25 per cent was contributed by eastern Kentucky. This discrepancy is due to the discovery of more new fields in western Kentucky rather than to a decrease in production in the eastern fields, where the average has been maintained by reconditioning and secondary recovery of old fields and further development of new pools reported for the first time in 1943. In all, 1103 wells were known to have been drilled in the state during 1944, of which 659 were drilled in western Kentucky and 444 in eastern Kentucky. The exact number of wells drilled for any year is never known, as drilling permits are not required except 'when it is planned to drill through a workable coal seam. Of the total number of wells drilled, 459 were oil wells, 229 gas wells and 415 dry holes. The monthly production was as follows: January........................... 659,496 February.......................... 658,606 March...................... ...... 711,619 April............................. 649,926 May............................... 754,892 June.............................. 730,369 July.............................. 761,762 August............................ 878,053 September...................... 863,150 October........................... 968,732 November........................ 961,999 December........................ . 898,636 Western Kentucky In western Kentucky 352 wells were completed as oil wells with a total initial production of 47,922 bbl. of oil, the average being 136 bbl. per well. Two wells produced gas, the total initial production being 1,594,000 cu, ft. One hundred and eighteon wildcat wells were drilled, of which 107 were dry holes and 11 were oil wells. Three of the latter proved to be the discovery wells of commercial pools. Twelve new pools were discovered during 1944, none of major importance, as indicated in Table 2. The Utley pool, due to a stratigraphic trap on the flank of a closed structure, found oil in the Mcclosky at 2565 ft. in the discovery well, with initial productioil of 1000 bbl. The average daily production is now 227 bbl. from seven wells. The East Poole field, with the discovery well in the Tar Springs sandstone at 1811

Jan 1, 1945

By R. C. Beckstrom

Russia's first "Petaletka'' has ended. Technically it did not succeed but practically it has been a great achievement in the petroleum industry. Out of the chaos of revolution and civil war Russia has developed her oil industry to second place in the world's production. For 1932 production of crude oil is estimated at 150,000,000 bbl. and refined products at 145,000,000 barrels. Russia has been able to give the petroleum industry every advantage that a government can extend to a fast growing industry. She has obtained all of her property by confiscation. Under government ownership, operation and control, her petroleum industry is not handicapped in any way by state rulings or by unnecessary competition in production, refining and marketing. There are no damage suits resulting from offsetting, flooding, repressuring, laying of pipe lines, building of docks or other necessary work. Russian oil fields2 have been easy to develop and operate. They lie advantageously to transportation for foreign markets. The chief disadvantages have been a lack of credit and technical cooperation, but the former is being overcome by the sacrifice of the people. They go without the comforts of life that all salable articles may be exported for the imports of modern machinery. Modern machinery is fast replacing the obsolete and worn-out equipment. Technical cooperation has been difficult because it has been necessary to train thousands of adults to do technical and mechanical work. Great quantities of pipe, tools and electrical equipment were necessary for the rapidly developing fields and refineries. The supplies have been inadequate and the quality poor. This lack of equipment, along with the untrained technical supervision, has been the cause of the proposed quota falling short. Fig. 1 shows the production for 1931 and 1932. During 1932 a large percentage of the oil was produced in the proven fields of the Caucasus.

Jan 1, 1933

By Marcelo Rebellato, Leonardo Silvestre, Zhang Yongqing, Felipe Bastos, Zhang Weiqiang

This work reviews the new version of GB1499.2-2018 Chinese national standard and specification, which governs the production of high-strength reinforcing hot rolled ribbed bars in China. In addition, it discusses the main concerns from Chinese rebar makers that might affect production and application of Nb-bearing rebars, like reheating temperature required to dissolve given niobium additions, the promotion of bainite microstructure and continuous yielding, as well as Nb strengthening effects. Through extensive investigation involving both thermomechanical laboratory simulations and industrial trial, the existing state and effects of Niobium along the reheating, rolling and cooling are illustrated. At the end, optimum processing conditions have been established to produce high strength rebars for the specified requirements. The adoption of new process conditions reflected in an amount of about 20.0 million tons of Nb-bearing rebar being produced in China in 2018 with required tensile properties and microstructure, and helped rebar makers to reduce production costs considerably. Based on production data, Niobium demonstrated positive strengthening effect for high strength rebars, in particular for small diameter rebars with earthquake resistant performance. What is more, the results of the research enrich the knowledge of the application of Niobium in steels when TMCP rolling is not used.

Oct 1, 2019

By W. J., Kroll

MOST people believe that rare metals are always, scarce in nature, expensive to make, and therefore useless despite some miraculous properties which might make them a cure-all. There are' some metals, which are quite frequent in nature, such as zirconium, which are called rare only because our present methods for making them are elaborate, thus forcing the manufacturer to sell them at a high price. There are also truly rare metals, such as gallium, which do not occur frequently in ores, but are easily reducible from their oxides. In these cases the price of the concentration operation is the decisive factor. The distribution of the elements in the earth's crust is no indication as to the availability of a metal; the concentration operation is the critical factor. Concentration is frequently obtained in the course of metallurgical operations for the extraction of other metals, and the rare metal may be enriched in by-products, flue dusts, mother liquors or precipitates from electrolyte purification as are indium, thallium, selenium, and tellurium. A periodic table of the rare elements may serve as a basis for discussion of their properties and to establish a program. (Table 1.)

Jan 1, 1946

By W. N. Key, L. C. Acton

Freeport Minerals Co.'s Ertsberg East underground operation typifies the cliche that all the "easy" ore deposits have already been found. Despite its location, in a remote Indonesian rain forest, and the effort and expense required to develop the ore body, the mine was developed on schedule, under budget, and with minimal disruption of the adjacent open-pit mining operation. Development of the Ertsberg East copper, gold, and silver ore body took less than two years after exploration drilling and feasibility studies were completed. In addition, the project came in well under its targeted budget of $101.5 million. Initial block caving and underground ore production took place last year. About 3 kt/d of Ertsberg's total 8.6 kt/d ore production is currently mined underground. This will increase to 5.4 kt/d by year's end. Underground operations will eventually account for all of Ertsberg's production, as the open-pit ore body is depleted. Freeport Minerals is currently studying the possibility of increasing total Ertsberg East production tonnage to 10.5 kt/d by 1983. The equipment, work practices, and development methods at Ertsberg East (Gunung Bijih Timur or "GBT"), while typical of other block caving mines, were modified for rapid mine development and maximum ore recovery. Located in the Irian Jaya province, "Gunung Bijih" is the Indonesian expression for the Dutch "Ertsberg" that in English means "ore mountain." "Timur" means "east" and relates to the fact that the new underground ore body lies about 1 km east of the open pit. The area surrounding GBT is mountainous, with peaks from 4.2-5 km. The underground mine adit and surface plant are located at a 3.6-km elevation. The mine, 4° south of the equator, gets 5.1 m/a of rain, but has an average daily temperature of only 13°C because of the mine's elevation.

Jan 7, 1981

By Steven G. Jansto

Nearly one third of the globally produced structural flat and long structural products are in the 0.11 to 0.16% carbon range. By definition, numerous steelmakers globally define this approximate carbon range as peritectic in their melting grade family within their organization. The metallurgical consequence is the result of numerous global structural specifications which allow carbon to wide carbon ranges resulting in quality issues. For example, such specifications as ASTM A588 set no minimum carbon and a 0.15 to 0.19%C maximum depending on the specific grade designated within the specification. This peritectic region is specifically challenging in production compared to less than 0.10%C because of solidification issues and a higher propensity for slab or billet cracking during continuous casting. During hot rolling, rejects and/or deviates are increased as well. The relative steelmaking operational cost of production is compared between peritectic and non-peritectic carbon compositions for a given specification.

Aug 17, 2017

By Fabio Mielli

In these times of increasing costs and diminished returns, energy consumption is one source of savings that remains relatively untapped in the mining sector. Typically, 15% to 40% of operational costs can be attributed to energy in mining operations. This ?process variable? is a complex, multi-faceted variable that involves government regulations, societal pressures, cost and competitiveness. A mining company able to successfully embrace an energy efficiency program is more often than not a successful mining company. Production optimization programs, relatively common today, provide increased production, increased availability of assets and, in many cases, improved quality. They generally ignore the energy question altogether. Production Energy Optimization combines reductions in energy consumption with production improvements to reduce the cost per unit of production while improving emissions reporting. An energy strategy in mining and mineral processing operations is a critical component of Production Energy Optimization. This strategy must support the financial and operational integrity of the business. Developing a successful energy strategy requires a well structured approach such as following: ??Understanding where energy is being used and why, ??Recommending and implementing energy conservation measures, ??Driving visibility to targets and results, ??Re-evaluating continuously. The objective of this paper is to help you better understand the process, tools and technologies that enable mining organizations today to address energy and sustainability issues more tactically and proactively.

Aug 1, 2013

By H. S. Gipson

A process that has come to be known locally as "multistage stabilization" has been developed in the Haft Kel field of the Anglo-Iranian Oil Co. in southwest Iran, for the recovery of casinghead gasoline. It consists in releasing the dissolved gases from the crude by stages, a practice common in many fields, but which, so far as is known, has nowhere been carried to the extent to which it is employed in Iran. It has been in use there for nearly nine years, during which time some 200 million barrels of crude have been handled by the process. This process of gasoline retention consists in preventing the greater part of the casinghead gasoline hydrocarbons (the butanes and pentanes) from ever leaving the crude, instead of allowing them to be vaporized and then recovered from the lighter gases by the usual compression or absorption processes. Its efficiency is fully equal to that obtained by the absorption process; its disadvantage is that it increases the quantities of ethane and propane in the crude sent to the refinery, but with the growing demand for propane this drawback is vanishing. When casinghead gasoline is recovered as a separate liquid in the Iranian fields, it is blended with the crude, as the only outlet is through the refinery, and the crude-oil pipe line offers the cheapest means of transportation. It is under these conditions that the retention of the butanes and pentanes in the crude by multistage stabilization is a most attractive process, possessing as it does the following advantages: (1) extreme simplicity, (2) low first cost, (3) easy installation! (4) practically 100 per cent operating-time efficiency, (5) no operators required, (6) no water or other services required, (7) negligible maintenance, (8) once established, very little routine testing is necessary. The one essential for reasonably efficient multistage stabilization is that the flowing pressures of the wells should be relatively high; i.e., they should not be less than about one-third the saturation pressure of the crude in the reservoir. This is a very general statement, of course, and much depends on the type of crude and its temperature.

Jan 1, 1940